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Question:

how to separate iron ore from silica?

when it is profitable project to start to separate iron ore from silica? mean when iron ore is what percentage? then how and what machines are needed?

Answer:

Lot of factors go into deciding whether ore not an ore body is worth processing, such as grade, ore type (hematite vs magnetite). Silica is a pretty common compound in an ore's mineralogy (as it's sand). You're after what are known as the cut-off grades which will also depend on ore type. magnetite: maybe 25-30% Fe; and hematite, maybe 60% Fe, are the current economic cut-off grades. (according to the site in the sources). Process of extraction is usually pyrometallurgical: smelting with a blast furnace (see links). involves crushing (crusher) then pelletization, and finally blasting which produces a slag and a molten Fe stream. From memory. Don't quote me on this, I've only briefly looked at iron, haven't worked with it or anything.

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